TM-55-1925-204-12 TUG Harbor Diesel 1200 H. P. Steel 100 Ft Design 3006 Flight One FSN 1925-375-3003 Manual

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TM-55-1925-204-12

TECHNICAL MANUAL OPERATOR AND ORGANIZATIONAL MAINTENANCE MANUAL TUG, HARBOR, DIESEL, STEEL,
WARNING
Operator and Organizational Maintenance Manual
By Order of the Secretary of the Army
Operator and Organizational Maintenance Manua
Operator and Organizational Maintenance Manual
Operator and Organizational Maintenance Manual
Operator and Organizational Maintenance Manual
Operator and Organizational Maintenance Manual
Operator's and Organizational Maintenance Manual
OPERATOR AND ORGANIZATIONAL MAINTENANCE MANUAL
LIST OF ILLUSTRATIONS
LIST OF ILLUSTRATIONS
LIST OF ILLUSTRATIONS - CONTINUED
LIST OF ILLUSTRATIONS - CONTINUED
LIST OF TABLES
CHAPTER 1 INTRODUCTION
Figure 1-2. Tug, harbor, diesel, 1,200 hp, steel, 100 foot, design 3006, port side.
Tabulated Data
Propulsion Data.
Auxiliary Set (Generator and Pump ).
Heating Unit.
Oil burning range.
Table 1-1. Torque Limits (Engine, Model 37F16)
Table 1-4. Operating Pressures (Engine Model 37F16)
CHAPTER 2 OPERATING INSTRUCTIONS
Figure 2-1. Pilothouse navigational controls.
Pilothouse Engine Controls.
Figure 2-2. After steering station.
Figure 2-3. Main engine controls.
Figure 2-3. Main engine controls. - CONTINUED
Figure 2-4. Auxiliary set engine controls and instruments.
Main Electrical Control Panel (Switchboard ).
Figure 2-5. Main electrical control panel ( switchboard)
Heating System Controls.
Figure 2-6 Heating boiler controls
Table 2-1. Heating System Control Valves.
Table 2-1. Heating System Control Valves.
Figure 2-7. Air compressor controls.
Table 2-2. Compressed Air System Control Valves.
Table 2-3. Raw and Fresh Water Engine Cooling System Control Valves.
Table 2-4 Fuel Oil System Control Values.
Table 2-5. Fire and Salvage System Control Valves.
Table 2-6. Lubricating Oil System Control Valves.
Figure 2-8. Water pressure set controls.
Table 2-7. Bilge and Ballast System Control Valves.
Table 2-8. Machinery Status Prior to Getting Underway.
Section II. OPERATION OF AUXILIARY EQUIPMENT
Figure 2-9. Fuel oil system piping diagram.
Figure 2-9. Fuel oil system piping diagram. - CONTINUED
Figure 2-10. Fuel oil capacity sounding charts.
Table 2-9. Fuel Oil System Control Valve Positioning.
Fuel Oil Pump Operation
Figure 2-11. Lubricating oil system piping diagram.
Lubricating Oil System Pump Operation.
Lubricating oil purifier system.
Figure 2-12. Lubricating oil purifier flow diagram.
Draining the purifier filters
Figure 2-13. Marine steering system arrangement.
Steering System Trick Wheel Operation.
Figure 2-14. Compressed air system piping diagram.
Air Compressor Operation.
Ventilation System Operation
Figure 2-15. Ships service power control panel wiring diagram
Figure 2-16. Engine room lighting control panel wiring diagram.
Figure 2-18. Pilothouse lighting control panel wiring diagram.
Figure 2-20. Battery charging control panel.
General Alarm System Operation.
Figure 2-22. Main electrical control panel wiring diagram, rear view.
Connect a generator to the control panel
To secure one generator from paralle
Figure 2-23. Engine cooling system diagram.
CO2 Fire Extinguishing Equipment Operation
Figure 2-24. Bilge and ballast piping diagram.
Figure 2-25. Chain locker bilge piping diagram.
Table 2-14. Bilge and Ballast System Control Value Positioning.
Figure 2-26. Fore peak tank capacity and soundings.
Figure 2-27. Aft peak tank capacity and soundings.
Figure 2-28. Fire and salvage system piping diagram.
Bilge and ballast pump operation.
Figure 2-29. Heating system piping diagram.
Table 2-16. Heating System Control Valve Positioning.
Anchor Windlass Operation
Figure 2-30. Markey model VEV-16 anchor windlass.
Figure 2-31. Galley range burner unit.
Refrigerator Operation
Figure 2-32. Water dispenser (cooler).
Figure 2-33. Gyro compass control cabinet.
Figure 2-34. Gyro compass master unit.
Starting the compass.
Section III. OPERATION UNDER, UNUSUAL CONDITIONS
Operation in Extreme Heat
CHAPTER 3 OPERATOR/CREW MAINTENANCE INSTRUCTIONS
PMCS Schedule
Table 3-1. Operator/Crew Preventive Maintenance Checks and Services Tug Diesel Large Design 3006
Table 3-1. Operator/Crew Preventive Maintenance Checks and Services - Continued Tug Diesel Large Design 3006
Table 3-1. Operator/Crew Preventive Maintenance Checks and Services - Continued Tug Diesel Large Design 3006
Table 3- Operator/Crew Preventive Maintenance Checks and Services - Continued
Table 3- Operator/Crew Preventive Maintenance Checks and Services - Continued
Table 3- Operator/Crew Preventive Maintenance Checks and Services - Continued
Table 3- Operator/Crew Preventive Maintenance Checks and Services - Continued
Table 3- Operator/Crew Preventive Maintenance Checks and Services - Continued
Table 3- Operator/Crew Preventive Maintenance Checks and Services - Continued
Table 3- Operator/Crew Preventive Maintenance Checks and Services - Continued
Table 3- Operator/Crew Preventive Maintenance Checks and Services - Continued
Table 3- Operator/Crew Preventive Maintenance Checks and Services - Continued
Table 3- Operator/Crew Preventive Maintenance Checks and Services - Continued
Table 3- Operator/Crew Preventive Maintenance Checks and Services - Continued
Table 3- Operator/Crew Preventive Maintenance Checks and Services - Continued
Table 3- Operator/Crew Preventive Maintenance Checks and Services - Continued
Table 3- Operator/Crew Preventive Maintenance Checks and Services - Continued
Table 3- Operator/Crew Preventive Maintenance Checks and Services - Continued
Table 3- Operator/Crew Preventive Maintenance Checks and Services - Continued
Table 3- Operator/Crew Preventive Maintenance Checks and Services - Continued
Section III. TROUBLESHOOTING
Table 3-3. Troubleshooting.
BLACK OR GRAY EXHAUST.
LACK OF OIL PRESSURE.
LOSS OF POWER.
OVERHEATING
MOTOR RUNS TOO SLOW UNDER LOAD
GRAVITY LESS THAN 1.215.
PUMP NOISY IN OPERATION
WINDLASS FAILS TO STOP AT SAME RATE OF SPEED AS STARTING
TEMPERATURE RISES
SEARCHLIGHT WILL NOT ROTATE OR ELEVATE
Figure 3-1. Cylinder head removal and installation.
Figure 3-2. Cylinder compression relief valve
Figure 3-3. Cylinder head valves.
Figure 3-4. Cylinder compression relief valve
Figure 3-5. Sequence of applying torque to HOLDDONE NUTS..
Figure 3-6. Piston, connecting rod, and rings.
Connecting Rod Bearings
Figure 3-7. Connecting rod bearing.
Cylinder Sleeve and Scraper Rings.
Figure 3-8. Cylinder, sleeve, and rings.
Cleaning, Inspection, and Repair of Piston and
Check bearing to journal clearance as
Figure 3-9. Fuel oil filters, lines and transfer (supply) pump.
Removal.
Figure 3-10. Fuel transfer (supply) pump, cross section.
Fuel Priming Pump
Figure 3-11. Fuel injection pump, cross section
Figure 3-12. Fuel injector (nozzle), cross section.
Figure 3-13. Fuel injection pump.
Fuel Injector (Nozzle)
Figure 3-14. Fuel injector removal and installation.
Governor (Mechanical)
Figure 3-15. Governor, (mechanical).
Test and Adjustment.
Figure 3-16. Half of twin fuel oil filter, cross section.
Figure 3-17. Filter element assembly.
Figure 3-18. Propulsion engine, port side view.
Disassembly
Figure 3-19. Scavenging pump, cross section.
Reassembly.
Oil and Water Pump Drive.
Figure 3-20. Oil and water pump drive.
Crankcase Breather
Figure 3-21. Crankcase breather, cross section.
Figure 3-22. Engine fresh and raw water pump.
Figure 3-23. Fresh or raw water pump, cross section.
Engine Raw Water Pump
Figure 3-24. Water inlet header and valve.
Lubrication Oil Pump (Engine)
Figure 3-25. Lubrication oil pump.
Lubrication Oil Cooler (Heat Exchanger)
Figure 3-26. Crankshaft and main bearings.
Replacement of Main Bearing.
Thrust Bearing (Kingsbury)
Figure 3-27. Thrust bearing (Kingsbury).
Propeller and Shaft
Figure 3-28. Engine order telegraph transmitter
Figure 3-29. Engine order telegraph indicator.
Windshield Wiper Removal.
Figure 3-30. Windshield wiper.
Cleaning, Inspection, and Repair of Engine order telegraph
Figure 3- 31. Intercommunicating telephone station ( typical).
Figure 3-32. Fire and salvage system manifold.
Figure 3-33. Eductor ( jet suction ).
Sea Valves, Strainers, and Sea Chests
Figure 3-34. Sea valve and sea chest ( typical).
Figure 3-35. Strainer location (typical)
CHAPTER 4 ORGANIZATIONAL MAINTENANCE INSTRUCTIONS
Figure 4-1. Fixed fire extinguisher piping arrangement.
Section II. REPAIR PARTS, SPECIAL TOOLS AND EQUIPMENT
Table 4-1. Special Tools, Test and Support Equipment
Section III. LUBRICATION INSTRUCTIONS
Table 4-3. Troubleshooting
Figure 4-2. Replacing typical component for suppressing radio interference
Section VII. MAINTENANCE OF THE PROPULSION ENGINE
Figure 4-3. Exhaust manifold section removal.
Figure 4-4. Air receiver (box) removal
Cleaning, Inspection, and Repair.
Figure 4-5. Air Distributor.
Removal.
Figure 4-6. Air start distributor and reverse control.
Installation.
Exhaust System
Figure 4-8. Exhaust manifold and outlet pipe.
Figure 4-9. Silencer (muffler).
Forced Feed Lubricator
Figure 4-10. The force feed lubricator.
Figure 4-11. Lubricator drive.
Figure 4-12. Force feed lubricator. sectional view.
Cleaning, Inspection and Repair.
Table 4-4. Force Feed Lubricator Drop Count
Figure 4-13. Scavenging oil transfer pump (#5130)
Figure 4-14. Motor controls.
Figure 4-15. Camshaft and bearings.
The Engine Electrical System
Figure 4-16. Instrument panel.
Figure 4-17. Flywheel jacking device.
Figure 4-18. Shutoff value, storage tank, and
Figure 4-19. Engine air brake cylinder.
Figure 4-20. Brake shoe and linkage.
Figure 4-21. Brake air cylinder.
Figure 4-22. Cam operated pilot air value
Figure 4-23. Pressure regulating value.
Cleaning, inspection, and repair.
CHAPTER 5 MATERIEL USED IN CONJUNCTION WITH THE TUG
Engine (Model 4061A) Accessories
Figure 5-3. Air cleaner, starter, and fuel filter.
Raw Water Pump. This pump supplies water to
Figure 5-4. Raw water pump, lines, and rocker arm cover
Figure 5-5. Fresh water pump, lines and governor.
Installation.
Figure 5-6. Blower, and air inlet housing.
Installation.
Figure 5-7. Belt guard, oil cooler, and engine mounting bolts
Figure 5-8. Engine generator and voltage regulator.
Figure 5-9. Exhaust pipe and elbow.
Figure 5-10. Water cooled exhaust manifold
Cylinder Head
Figure 5-11. Removing injector control shaft and fuel lines.
Figure 5-12. Rocker arms and push rods.
Figure 5-14. Removal of valve seat.
Figure 5-15. Sequence of tightening cylinder head nuts.
Pistons, Connecting Rods, and Piston Rings
Figure 5-16. Piston, connecting rod,cylinder and rings
Figure 5-17. Measuring piston clearance.
Figure 5-18. Measuring piston ring end gap.
Figure 5-19. Checking piston ring side clearance.
Figure 5-20. Compressing the piston rings.
Figure 5-22. Cylinder liner measurement diagram.
Figure 5-23. Cylinder liner removal.
Figure 5-24. Cylinder liner mounted in block.
Support the flywheel
Valves, Camshaft, and Timing System
Figure 5-25. Installing valve seat.
Figure 5-26. Balance weight cover removal and capscrew tightening sequence.
Figure 5-28. Idler gear details and location of parts.
Cleaning, inspection, and repair.
Figure 5-29. Gear train and timing marks. L. H. rotation.
Adjusting valve clearance-engine cold.
Figure 5-30. Adjusting the valve clearance.
Cleaning, inspection, and repair.
Figure 5-31. Crankshaft, main, and thrust bearings.
Figure 5-32. Removing main bearing upper half (with crankshaft in place).
Installation.
Figure 5-34. Typical vibration damper details.
Figure 5-36. Crankshaft front cover attaching hardware tightening sequence.
Cleaning, inspection, and repair.
Figure 5-37. Checking cranking end play.
Prepare the cylinder block for pressure test as
Oil Pump (Engine Lubricating)
Figure 5-39. Engine lubricating oil pump.
Figure 5-40. Lubricating oil filter .
Fuel Injector
Figure 5-41. Fuel injector mounting.
Figure 5-42. Fuel injector.
Cleaning, Inspection, and Repair.
Figure 5-43. Injector tester.
Installation.
Figure 5-44. Timing fuel injectors.
Figure 5-45. Fuel transfer pump.
Fuel Filter and Strainer
Figure 5-46. Typical fuel strainer (filter)
Governor Adjustment.
Figure 5-47. Adjusting fuel rod.
Figure 5-48. Adjusting for maximum fuel.
Figure 5-49. Positioning injector control rack.
Figure 5-50. Adjusting speed droop.
Figure 5-51. Setting maximum speed adjusting screw.
Figure 5-52. Hydraulic governor mountings.
Air Cleaner
Figure 5-53. Typical air shutdown (inlet) housing
Figure 5-54. Heat exchanger.
Installation.
Figure 5-55. Lubrication oil cooler and fresh water line.
Figure 5-56. Typical water manifold mounting.
Reassembly.
Figure 5-57. Fresh water pump.
Figure 5-58. Raw water pump.
Exhaust Manifold, Pipes, and Muffler
Engine Generator
Starting Motor
Figure 5-59. Starting motor.
Engine Instrument Panel
Figure 5-60. Engine instrument panel.
Tachometer and Drive Shaft
Figure 5-61. Generator removal and installation
Figure 5-62. Delco 40-kw, 120-volt dc generator.
Figure 5-63. Stud alignment.
Figure 5-64. Brush holder alignment.
Figure 5-65. Clutch and pump removal.
Figure 5-66. Clutch arrangement (Model CL208)
Figure 5-67. Fire and salvage pump.
Bilge and Ballast Pump
Figure 5-68. Bilge and ballast pump removal.
Figure 5-69. Bilge and ballast pump.
Priming Pump
Figure 5-70. Priming pump.
Figure 5-71. Bilge and ballast pump motor.
Controller
Figure 5-72 Bilge and ballast pump accelerating contactor.
Figure 5-73. Overload Relay.
Fire Pump
Figure 5-74. Fire pump removal.
Figure 5-75. Fire pump.
Motor
Figure 5-76. Fresh and salt water standby pump, removal.
Figure 5-77. Fresh and salt water standby pump.
Fuel Oil Transfer Pump
Figure 5-78. Fuel pump, cutaway.
Cleaning and Inspection.
Figure 5-79. Checking coupling alignment.
Figure 5-80. Controller, fuel oil transfer pump motor, schematic diagram.
Figure 5-81. Overload relay.
Figure 5-82. Accelerating contactor.
Figure 5-83. Lead dimensions.
Figure 5-84. Auxiliary contacts.
Lubricating Oil Standby Pump
Figure 5-85. Lubricating oil standby pump.
Figure 5-86. Lubricating oil standby pump, section.
Motor
Figure 5-87. Motor, lubricating oil standby pump drive.
Figure 5-88. Controller contactor.
Figure 5-89. Lubricating oil purifier.
Figure 5-90. Oil purifier assembly.
Figure 5-91. Sectional view of bowl.
Cleaning, inspection, and repair.
Figure 5-92. Pumps and clutches, sectional view.
Cleaning, inspection, and repair.
Heater and Filter Unit.
Fresh Water and Sanitary System Pump (No. 1892)
Figure 5-93. Fresh water pump and motor.
Figure 5-94. Water pump
Relief Valve
Rotary Hand Pumps
Figure 5-95. Lubricating oil rotary hand pump.
Figure 5-96. Rotary hand pump (typical).
Figure 5-97. Air compressor.
Figure 5-98. Air compressor, low-pressure control valves.
Figure 5-99. Air compressor, high pressure control valve.
Figure 5-100. High-pressure diaphragm unloader
Pistons and Connecting Rods.
Figure 5-101. Air compressor.
Installation.
Figure 5-102. Motor removal and belt adjustment.
Section IV. ANCHOR WINDLASS-CAPSTAN SYSTEM
Figure 5-103. Anchor windlass brake arrangement.
Figure 5-104. Anchor windlass motor and gear box
Figure 5-105. Anchor windlass, Type VEV-16.
Cleaning, Inspection, and Repair.
Figure 5-106. Anchor windlass and master switch.
Figure 5-107. Capstan.
Figure 5-108. Motor brake, capstan.
Master Switch
Figure 5-109 Master switch control assembly
Section V. HEATING SYSTEM
Figure 5-110. Heating boiler burner unit and mounting.
Figure 5-111. Oil burner assembly
Maintenance and adjustment.
Section VI. VENTILATING SYSTEM
Figure 5-112. Typical centrifugal blower assembly.
Controller
Axial Blower Assembly
Figure 5-113. Axial blower assembly (looking up ) for engineroom exhaust.
Figure 5-114. Axial blower assembly, sectional view.
Controllers
Section VII. WATER SUPPLY SYSTEM
Figure 5-115. Typical wash room fixture placement.
Section VIII. FOOD PREPARATION SYSTEM
Fuel oil metering control valve.
Figure 5-116. The refrigerator compressor unit,
Figure 5-117. Freezer for cold storage of food.
Section IX. MAIN ELECTRICAL SYSTEM
Voltmeter
Figure 5-118. Battery charging panel.
General Lighting Panel
Figure 5-119. Engineroom general alarm bell
Section X. STEERING SYSTEM
Figure 5-120. Motor and brake.
Figure 5-121. Rudder travel stop adjustment screws.
Figure 5-122. Hydraulic ram assembly.
C Hydraulic Pump.
Figure 5-123. Hydraulic pump.
Steering Console, Hand Pump, and Valves
Figure 5-124. Valve and fittings.
Figure 5-125. Steering console.
Figure 5-126. Pump, hand, hydraulic.
Figure 5-127. Gears, universal joints, and couplings.
Figure 5-128. Miter gear box, L. H.
Figure 5-129. Miter gear box, R. H.
Figure 5-130. Miter gear box, differential
Section XI. NAVIGATION EQUIPMENT
Section Xll. SEARCHLIGHT EQUIPMENT
Figure 5-131. Searchlight atop pilot house.
Searchlight
Figure 5-132. Searchlight, cross section.
Section Xlll. FIRE FIGHTING EQUIPMENT
Figure 5-133. Typical portable extinguisher position.
Figure 5-134. Pull box (activation ).
Figure 5-135. Remote control lever release.
Figure 5-136. Air whistle and electric horn.
Section XVI. LIFE BOAT DAVIT
APPENDIX A REFERENCES
APPENDIX A REFERENCES - contineud
APPENDIX B OPERATOR/BOAT SET LIST COMPONENT OF END ITEM, BASIC ISSUE ITEMS, ADDITIONAL AUTHORIZATION AND EXPENDABLE SUPPLIES AND MATERIEL LISTINGS
Section II COMPONENTS OF THE END ITEM LIST (COEIL)
Section III (Continued)
Section III (Continued)
Section III (Continued)
Section III (Continued)
Section III (Continued)
Section IV. COMPONENTS OF END ITEM (COEI) ON-BOARD REPAIR/SPARE PARTS SPECIAL TOOLS
Section IV. COMPONENTS OF END ITEM (COEI) ON-BOARD REPAIR/SPARE PARTS SPECIAL TOOLS - continued
Section IV. COMPONENTS OF END ITEM (COEI) ON-BOARD REPAIR/SPARE PARTS SPECIAL TOOLS - continued
Section IV. COMPONENTS OF END ITEM (COEI) ON-BOARD REPAIR/SPARE PARTS SPECIAL TOOLS - continued
Section IV. COMPONENTS OF END ITEM (COEI) ON-BOARD REPAIR/SPARE PARTS SPECIAL TOOLS - continued
Section IV. COMPONENTS OF END ITEM (COEI) ON-BOARD REPAIR/SPARE PARTS SPECIAL TOOLS - continued
Section IV. COMPONENTS OF END ITEM (COEI) ON-BOARD REPAIR/SPARE PARTS SPECIAL TOOLS - continued
Section IV. COMPONENTS OF END ITEM (COEI) ON-BOARD REPAIR/SPARE PARTS SPECIAL TOOLS - continued
Section IV. COMPONENTS OF END ITEM (COEI) ON-BOARD REPAIR/SPARE PARTS SPECIAL TOOLS - continued
Section IV. COMPONENTS OF END ITEM (COEI) ON-BOARD REPAIR/SPARE PARTS SPECIAL TOOLS - continued
Section IV. COMPONENTS OF END ITEM (COEI) ON-BOARD REPAIR/SPARE PARTS SPECIAL TOOLS - continued
Section V. DAMAGE CONTROL EQUIPMENT
Section V. DAMAGE CONTROL EQUIPMENT
Section VI. EXPENDABLE SUPPLIES AND MATERIAL LIST
Section VI. EXPENDABLE SUPPLIES AND MATERIAL LIST - continued
Section VI. EXPENDABLE SUPPLIES AND MATERIAL LIST - continued
Section VI. EXPENDABLE SUPPLIES AND MATERIAL LIST - continued
APPENDIX C MAINTENANCE ALLOCATION CHART (MAC)
Section II. MAINTENANCE ALLOCATION CHART
Section II. MAINTENANCE ALLOCATION CHART - continued
Section II. MAINTENANCE ALLOCATION CHART - continued
Section II. MAINTENANCE ALLOCATION CHART - continued
Section II. MAINTENANCE ALLOCATION CHART - continued
Section II. MAINTENANCE ALLOCATION CHART - continued
Section II. MAINTENANCE ALLOCATION CHART - continued
Section II. MAINTENANCE ALLOCATION CHART - continued
Section II. MAINTENANCE ALLOCATION CHART - continued
Section II. MAINTENANCE ALLOCATION CHART - continued
Section II. MAINTENANCE ALLOCATION CHART - continued
Section III. SPECIAL TOOLS AND TEST EQUIPMENT
Section III. SPECIAL TOOLS AND TEST EQUIPMENT - continued
INDEX
INDEX - continued
INDEX
INDEX
INDEX
INDEX
INDEX
INDEX
TM-55-1925-204-12
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By Order of the Secretary of the Army: